1. QUARRIES PROCESS DESCRIPTION

2. 2 Quarries PROCESS DESCRIPTIONS 1.Primary A.Vibrating feeder B.Crusher or primary mill 2.Secondary A.Vibrating machines B.Transport bands C.Gravel bins D.Secondary mills 3.Third Part A.Transport bands B.Sander mills C.Output transport bands 4.Criteria of use for Power Electronics equipments SUMMARY

3. 3 General Process PRIMARY 1

4. 4 A. VIBRATING FEEDER Quarries – Process Description SAND AND GRAVEL PITS ENTRANCE: The biggest stones are transported directly to the main feeder using lorries. The main vibrating feeder is the responsible of regulating the material entrance flow to the next stage. The motors used have powers around 40-75HP approximate. » Primary material entrance» Material at primary crusher

5. 5 From the main feeder, the material goes to the crusher or Primary Mill, where the biggest stones start to be crushed. Those mill could be: » Crusher Jaw  VSD. » Crusher of Bars Rotor. In these cases, power is around 340HP. B. CRUSHER OR PRIMARY MILL » Primary mill » Motor of primary mill Quarries – Process Description SAND AND GRAVEL PITS

6. 6 General Process SECONDARY 2

7. 7 In the secondary, the vibrating machine starts the vibrating screen according to the grain size (granulometry), and this material is dosed to the corresponding transport bands. In this stage power around 75HP are used and its common the use of variable speed drives to keep constant the production flow. A. VIBRATING MACHINES » Vibrating machine – Coarse screen 01» Vibrating machine – Coarse screen 02 Quarries – Process Description SAND AND GRAVEL PITS

8. 8 The transport bands lead the material to the gravel bins. The material which is out of range (gravel size) is not transported to those bins but it is lead back to the previous crushing stage. These are called feedback transport band. Now we should consider motors around 10 and 30HP. The drives controlling these transport band is able of regulating the speed to warranty the correct level in the bins. B. TRANSPORT BANDS » Transport bands 01» Transport bands 02 Quarries – Process Description SAND AND GRAVEL PITS

9. 9 Normally the end of the transport band is directly placed on the top of the bins, where the material is stocked, although this depends on the quarry distribution. In some cases, the end of the transport band is in the open air. The vibrating machine placed afterwards will allow to dose the correct quantity to the mills. C. GRAVEL BINS » Stock bins 01» Stock bins 02 Bins Bins Quarries – Process Description SAND AND GRAVEL PITS

10. 10 The secondary mills will realize a second milling. The granulometry is directly linked to the speed. So that, the variable speed drive will increase the mill speed up if a smaller gravel is required. The relation between the gravel size and the speed is inversely proportional. D. SECONDARY MILL » Secondary mill Those mills are provided with motors with a approximate power of 340HP. Two different kind of mills can be implemented in this stage: » Hammer mills  VSD. » Bars Rotor mills  Non VSD. Quarries – Process Description SAND AND GRAVEL PITS

11. 11 General Process THIRD PART 3

12. 12 These transport bands have the same functionality than the described for the secondary stage. The difference is the gravel size of the material transported. Some times, they are closed to avoid the fallen of material and objects (safety reasons). A. TRANSPORT BANDS » Transport bands on third stage 01» Transport bands on third stage 02 Quarries – Process Description SAND AND GRAVEL PITS

13. 13 The sander mills are hammer mills. They are managed with motor of 75 and 200HP power. In addition to the previously reason described for using VSD, it should be considered that in that kind of mills it is possible to change the running direction (FORWARD – REVERSE) to prevent the hammer wearing. B. SANDER MILLS » Sander mill Quarries – Process Description SAND AND GRAVEL PITS

14. 14 Now again there are some transport band, in the last stage, to transport the final products to the loading area for the lorries. It could be in open air stoke piles or in loading docks. C. OUTPUT TRANSPORT BANDS » Output conveyors 01» Output conveyors 02 Bins Loading docks Open air stoke piles Quarries – Process Description SAND AND GRAVEL PITS

15. 15 Criteria of use for Power Electronics Equipments VARIABLE SPEED DRIVES & SOFTSTARTERS 4

16. 16 Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS

17. 17 » PRIMARY FEEDERS: Variable Speed Drives » Power around 40 – 75HP approximately Recommended equipments: » SD700 Series - Frame 4 » SD450 Series - Frames 5 and 6 [ POWER ELECTRONICS EQUIPMENTS USE JUSTIFICATION ] PRIMARY – ACTUATORS FOR VIBRATING FEEDER To keep a correct dosage to the crusher input. By mean of this control, we try to obtain the maximum efficiency of the crusher motor. The VSD allows controlling the speed to control in this way the production process. Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS

18. 18 Primary crushers are classified according to: » JAW CRUSHER: Variable Speed Drives (power around 340HP approximately) » BARS ROTOR CRUSHER Recommended equipments: » SD700 Series PRIMARY – ACTUATORS OF THE CRUSHER Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS [ POWER ELECTRONICS EQUIPMENTS USE JUSTIFICATION ] The VSD is used as softstarter. Changing the speed it is possible to modify the size of the crushed stones. If the speed is increased up, the gravel size is smaller. If the speed is decreased, then the gravel size increases. This avoid the grid changing each time a different gravel size is required. If we consider that each grid changing means around 1 hour, we are talking about a considerable saving in production costs. When the crusher should start with load normally appears problem due to the high resistant torque, but the drive can perfectly control this situation by setting the starting parameters. Power supply lost means no additional problems then.

19. 19 Primary crushers are classified according to: » JAW CRUSHER: Variable Speed Drives (power around 340HP approximately) » BARS ROTOR CRUSHER Recommended equipments: » SD700 Series PRIMARY – ACTUATORS OF THE CRUSHER Additionally is possible to prevent blocking problems, since it is possible to crush gradually. Important savings are getting since the machine do not need to be download due to a stone blocking (times higher than 1 working day). Damage for the workers that should realize the un- blocking is avoided. Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS [ POWER ELECTRONICS EQUIPMENTS USE JUSTIFICATION ]

20. 20 » SECONDARY VIBRATING MACHINES: Variable Speed Drives » Motor power is around 75HP approximately Recommended equipments: » SD700 Series – Frame 5. » SD450 Series – Frame 7. SECONDARY – ACTUATORS FOR VIBRATING MACHINE The objective is to control the material arriving to the mills, in order to not saturate them. Production optimizing in order to get the mills operating at maximum efficiency but avoiding breakings. Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS [ POWER ELECTRONICS EQUIPMENTS USE JUSTIFICATION ]

21. 21 » TRANSPORT BANDS: Variable Speed Drives » Motor power is around 10 – 30HP approximately Recommended equipments: » SD700 Series. » SD450 Series. ACTUATOR FOR GENERAL TRANSPORT BANDS The objective is to control the material arriving to the stocked bins to keep the level under control. To avoid start and stop. In some cases, there are open bins where the level is visually controlled. In those cases softstarters are commonly used, so V2 and V5 series use is recommended according to different power. Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS [ POWER ELECTRONICS EQUIPMENTS USE JUSTIFICATION ]

22. 22 » SECOND AND THIRD STAGES VIBRATING MACHINES: Variable Speed Drives » Motor power is around 15 – 20HP and 2 – 10HP approximately. Recommended equipments: » SD700 Series (small power). » SD450 Series (small power). » SD250 Series. ACTUATORS FOR VIBRATING MACHINES IN SECOND AND THIRD STAGES The objective is to control the material arriving to the mills, in order to not saturate them. Production optimizing in order to get the mills operating at maximum efficiency but avoiding breakings. Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS [ POWER ELECTRONICS EQUIPMENTS USE JUSTIFICATION ]

23. 23 » SECONDARY MILLS: Variable Speed Drives » Power are around 300 – 350HP approximately. Recommended equipments: » SD700 Series (small power). ACTUATORS FOR SECONDARY MILLS To modify the speed to control the granulometry. Production optimizing because the grids changing does not exist any longer and the lines must not be stopped. The starting is controlled in the same way as described for the primary crusher. Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS [ POWER ELECTRONICS EQUIPMENTS USE JUSTIFICATION ]

24. 24 » SANDER MILLS: Variable Speed Drives » Motor power is around 75 – 200HP approximately Recommended equipments: » SD700 Series (small power). » SD450 Series. ACTUATORS FOR SANDER MILLS To modify the speed to control the granulometry. Production optimizing because the grids changing does not exist any longer and the lines must not be stopped. The starting is controlled in the same way as described for primary crusher. This mills are hammer mills, so that it is possible to make them operate in reverse mode to avoid and prevent the wearing of the hammers (instead of crushing using only one face, it will be possible to crush using both faces of the hammers – maintenance saving ). Note: Some manufactures are: COFANCO, MAGOTEAUX, LARON. Quarries CRITERIA OF USE FOR POWER ELECTRONICS EQUIPMENTS [ POWER ELECTRONICS EQUIPMENTS USE JUSTIFICATION ]

25. 25 SD700 SERIES - FRAME 4 SD450 SERIES - FRAME 7 SD700 SERIES - FRAMES 6 AND 7 SD700 SERIES - FRAME 5 SD450 SERIES - FRAME 7 SD700 SERIES SD450 SERIES SD700 SERIES SD450 SERIES COMPLETE LINE: ACTUATORS SUMMARY Quarries PROCESS DESCRIPTION SD700 SERIES SD450 SERIES SD250 SERIES SD700 SERIES

26. Thanks for your attention Presentation QUARRIES: Process description Realized Pilar Navarro Organized Marketing Department www.power-electronics.com ©2006 Power Electronics, S.L.